Paper roll



N. MARCALUS PAPER ROLL Original Filed' Aug. 19, 1930 2 SheetS-Shet Oct..25, 1932. N, MARCALUS '1,884,784

PAPER ROLL original Filed Aug. 19, 1930'y 2 sneets-sheet 2 INVENTOR/a/as /l/arc'a /05/ 6 W, 337m* muda ATTORN EY5 Patented Oct. 25, 1932UNITED STATES PATENT OFFICE NIGHOLAS MAROAL'US, OF ELIZABETH, NEWJERSEY, ASSIGNOB TO AUTOMATIC PAPER MACHINERY C0. INC., .A CORPORATIONOF NEW JERSEY PAPER BOLL Original application filed August 19, 1930,Serial No. 476,428. Divided and this application filed June 9, 1931.Serial No. 543,063.

This invention relates to a paper roll, the present applicationconstituting a division of my copending application Serial No. 47 6,428filed August 19, 1930.

It is common commercial practice to retail paper wound upon cardboardcores, for example waxed paper used for wrapping foods. For conveniencein merchandising, as well as in using, these rolls are usually madeabout twelve inches long so that the width of the wound strip is onlytwelve inches. For many uses a wider strip is desirable; for example,tissue paper used for wrapping gifts at Christmas time is always morethan twelve inches wide. In order to get a wider wound strip either alonger core and longer package must be used or the strip must be foldedbefore winding. It would be simple enough to wind a` wider strip, but aroll, substantially longer, say twenty-four inches long would be awkwardto handle both for the merchant and for the user. The alternative, towind a folded web, presents dificulties. The inner ply invariablybuckles and when unwound is found to be badly wrinkled. Such a productis unattractive and is not commercially desirable. Another diflicultyinherent in the winding of folded webs is this: The thickness at thefold is always more than twice the thickness of the single ply unlessthe fold be so sharp as to rupture the fibers-thus as the windingproceeds the diameter of the roll at the fold increases faster thanelsewhere,` complicating the winding and producing a misshapen wrinkledroll. It is, therefore, my object to produce a tightly wound roll offolded material free from wrinkles and of uniform dameter.

Now the reason the inner ply of a folded web buckles and wrinkles whenwound is that in winding, the outer ply must travel farther than theinner, being wound in effect upon a core larger, by the thickness of theweb itself, than the core upon which the inner ply is being wound. Andyet both plies are of the same length and being of one piece must traveltogether without relative 'slippage. Thus either the outer ply must tearor the inner ply must wrinkle. Because of the tensile strength of thepaper the inner ply usually wrinkles. In accordance with the presentinvention I elongate the outer ply relative to the inner before windingjust enough to compensate for the difference in winding length betweenthe two plies. This relative elongation may be effected by stretchingthe outer ply, causing an actual shift in the fibers themselves, or bycrimping the web transversely so that a diiferential elongation of thetwo plies is automatically efected during winding. In order to wind asmooth roll of uniform diameter despite the increased thickness of thematerial at the fold, I cause the core to traverse longitudinally duringthe winding so that the folded edge does not wind upon itself, eachconvolution being slightly 'displaced axially with reference to itspredecessor.

In my copending application above-preferred to I have described andclaimed a web winding machine adapted to crimp, fold and wind a web ofpaper into a roll. The present application is directed to the roll offolded paper.

In the accompanying drawings I have illustrated a preferred embodimentof my invention. In these drawings Figure 1 is a side elevation of thepaper roll; Figure 2 is a horizontal section through the roll; Figure 3is an enlarged detail showing the structure of the web at the fold;Figure 4 is a diagrammatic illustration of a folded web wound inaccordance with the present invention; Figure 5 is a similar viewshowing the buckling of the inner ply on a folded web wound underordinary conditions; Figure 6 illustrates the condition of the web ofFig. 5 when unrolled and opened out flat; Figure 7 is a sectional detailshowing mechanism which may be employed for folding the web and windingit upon a core to form a folded paper roll; Figure 8 is a diagrammaticview showing the crimping rollers; and Figure 9 is a detail, very muchenlarged and exaggerated showing the relation between inner and outercrimped plies on a wound roll.

I shall first refer to Figs. 4 and 5 and describe in some detail ustwhat happens when a folded web is wound. In these figures, 20

represents a web folded at 21 to form an inner ply 22 and outer ply 23.

Let R=the radius of curvature of the inner ply at any given point, T=the thickness of the web, and

S=the space between the two plies.

Although for any given convolution the cross section of each ply isspiral rather than truly oircular, the error involved in considering theform as circular is small and can be disregarded. For any givenconvolution, therefore: r V

Length of outervply=27r(R+ T+S) i VLength of inner ply=21rR I.

Difference in length=2zr(T+S) It is clear, therefore, that for everyconvolution the length of the outer ply must exceed the length of theinner ply by 6.28'times the -thickness of the web plus the space betweenthe two -plies' a constant for any givenV paper and tightness ofwinding.

i As a result of this disparity, a loosely wound folded web will assu'meroughlythe form illustrated in Figure with the inner ply bucklingat'points'24. VWhen the roll is tightly wound, as it mustl be incommercial practice, these bulges 24are flattened out' and form creasesor wrinkles 25 which remain as such in the paper when it is unwound andflattened, as i'llustrated in Figure 6. I avoid this by elongating theouter ply before winding an amount substantially equal to the'differencein length. 7

Referring now to Figure 3 it will benoted that where' the paper isfolded at 21, a loop sfOrmed' having a greater tliickness than twice thethickness of the plies. To make Va .sharper fold would rupture thefibres and weaken the paper along the fold when it is unfolded 'for use;VIf a folded web is wound in the ordinary fashion, the diameterof theroll, at the fold, will increase more rapidly than throughout the bodyofv the'roll. i In order to avoid this, I wind the folded web helically,as illustrated in Figures 1 and 2 in which 26 indicate"s-the cardboardcore on which the web is wound. As illustrated in these views the web isdisplaced relative to the core as the winding proceeds sothatrsuccessive convolutions of the fold do not overlap. This machineand method forms the subject matter of my copending application SerialNo. 476,428 above referred to.

In my copending application above referred to there is described indetail a machine for folding and winding a web of paper upon a core.According to the machine therein described the'web is unwound fromiaparent roll, is drawn over a folding former which folds the web to makea two-ply strip and then winds the folded strip upon a cardboard core.The folding former 42, 'feed rollers 43,

44 and Winding rollers 45, 46 and 47 of such a machine are shown in Fig.7.

The folding former 42 is provided along its paper-contacting edges withbars 49 and 50 over which the web passes during the folding operation.In order to stretch half of the web, that half which is to form theouter ply during winding, I provide means for adjusting the bar 49 sothat it may be raised above the bar 50 andthus increase the path whichthat half of the web passing it must travel,

'thus vcausing a slight elongation of that half ofthe web. Thisadjustment of the bar 49 is efiected by means of a series of set screws51. In order to facilitate the stretching operation steam may bedischarged' upon 'the por-- tion of the web to be stretched as forexample by means of a steam Chamber which has one of its sides closed bythe web itself as described in my cop'ending application. Only that halfof the web which'is to be stretched is subjected to this dampeningtreatment. The. 'folded web then passes downward through feed rollers 43and 44 to the core 26 which is held by three winding rollers 45, 46 and47. These winding rollers wind the folded web upon the 'core by surfacecontact. Winding roller 47 is swingingly mounted to move outward as thediameter of theiwound roll increases. During 'winding the core is givena continual longitudinal displacement so that the core of each rollismovedlongitudinally away from' the fold of the winding web thusproducing the set back construction illustrated in Figs. 1 and 2. v

Another means' for Varying the relative vlengths of the' inner and'outerpiles is illustrated in Figure 8. The rollers 40 and'41 arereplaced by longitudinally corrugated rollers 40'and 41' so' that theweb is crimped transversely as it passes between them. A crimped web canbe'elongated, slightly, even .when under winding ,tension,'withoutdeformation of the fibers; thus when a crimped web is folded and woundthe outer ply autom'atically elongates just sufficientto Compen- Satefor Vits greater length of.travel,' and wrinkling" is avoided.Therelationfof the ,two plies is illustrated in Figure 9'fro1n whichAitwill `be observed that the outer ply has been flattened slightly morethan the inner. 'No special stretchingmechanism is required and therelativeelongation automatically decreases with increase in the diameterof the roll. Despite the fact that the two piles of a. double-woundcrimp roll are of slightly different lengths and that a residual crimpremains, a relatively tight roll can be wound by this method. i

The product of my linvention is a tightly wound folded* strip free fromcreases and wrinkles and of uniform diameter. The outer stretched plymay be longer than the inner so that if the entire strip' were unwoundand un- -folded it would'curve' sligh'tly toward the inner ply. However,When relatively short Sections are torn from the roll this difference inlength is imperceptible. My invention is particnlarly useful inconnection With rolls of Wrapping paper, especially the tissue used forWrapping gifts. A Wide full Sheet may be unwound from a short, easilyhandled roll.

I claim:

1. A tightly Wound roll of paper, said roll consisting of convolutions,each convolution colnprising two plies integrally joined by alongitudinally folded area or line, the Web constituting the onter plybeing constructed of greater length than the inner ply of the sameconvolution, and each convolution being in a substantially smooth andunwrinkled condition.

2. A tightly wound roll of paper, said roll consisting of convolutions,each convolution comprising two plies integrally joined by alongitndinally folded area or line, the Web constituting the outer plybeing constructed of greater length than the inner ply of the sameconvolution, each convolution being in a substantially smooth andunwrinkled condition, and the folded area or line present in theconvolutions being aXially displaced With respect to each other.

3. A tightly Wound roll of snbstantially nonelastic paper, said rollconsisting of con- Volutions, each convolntion consisting of two pliesintegrally joined along a longitudinal fold line, the exterior ply ofeach convolution being greater in length than the interior ply and eachconvolution being' in a substantially smooth and unwrinkled condition.

4. A tightly wound roll of substantially nonelastic paper, said rolleonsisting of convolutions, each convolution consisting of two pliesintegrally joined along a longitudinal fold line, the exterior ply ofeach convolution being greater in length than the interior ply, eachconvolution being` in a substantially smooth and unwrinkled conditionand the fold lines present in the convolutions being axially displacedWith respect to each other.

In testimony Whereof I affix my signature.

NICHOLAS MARCALUS.

